[PPT]Industrial Safety - Ningapi.ning.com/.../INDUSTRIALSAFETY.ppt · Web viewTitle Industrial...
Transcript of [PPT]Industrial Safety - Ningapi.ning.com/.../INDUSTRIALSAFETY.ppt · Web viewTitle Industrial...
INDUSTRIAL HAZARDS AND SAFETY
Prof. Dr. Basavaraj K. Nanjwade M. Pharm., Ph. D
Department of PharmaceuticsKLE University College of Pharmacy
BELGAUM-590010, Karnataka, IndiaCell No: 00919742431000
E-mail : [email protected]
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CONTENTS
• Introduction• Types of hazards• Recommendations and Suggestions • Industrial effluent testing and treatment• Discussion on industrial accident case
studies• Questions • References
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Industrial hazards:
It can be defined as any condition produced byindustries that may cause injury or death topersonal or loss of product or property.
INTRODUCTION
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Heat and Cold
Burns
Heat stroke
Heat cramps
Foot sore
Immersion foot
Frost bite
Preventive Measures
A reasonable temp. of 20-250C must be maintained
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Auditory Non auditory effects Preventive measures a. At source:• Source of noise can be enclosed with an insulation
material or concrete wall.• Proper maintenance of machineryb. By distancec. Personal protection against noise.
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Noise have two type of effects
Equipment noise sources ,level & potential control solutions
Equipment Sound level in dBA at 3 feet
Possible noise control treatments
Air coolers 87-94 Aerodynamic fun blades,↓ revolutions/min ↑ pitch,↓ pressure drop
Compressors 90-120 Install mufflers on intake,& exhaust, enclosure the machine with casing, vibration isolation & lagging of piping system
Electric motors 90-110 Acoustically lined fun covers, enclosure 7 motor mutes
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Heater & furnaces
95-110 Acoustic plenums, intake mufflers, lined & damped ducts
Valves <80-108 Avoid sonic velocities, limit pressure drop & mass flow, replace with special low noise valves
Piping 9-105 Inline silencers, vibration isolation
Equipment noise sources ,level & potential control solutions
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Radiation Radiation are divided into two groups
Natural Man madeCosmic rays Medical /dental x-rays isotopes
Environmental (radioactive elements e.g. uranium)
Occupational exposure
Internal (potassium,) Nuclear radioactive fallout
Approx 0.1 rad/yr Miscellaneous
Use of radio active substances by different industries
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Somatic Genetici. Preventive measuresii. Radiation source should be housed in a building
that shields any surrounding area.iii. Radiation badges should be worn.iv. Periodical medical examination.v. Proper use of lead shields & lead rubber aprons.
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Effect of hazards
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CausesSmoking in the factoryDefective heating equipment, electrical equipment & wiring.Explosive gas leakage.Inadequate protection of electric motorsSparking of electric wires & equipmentProtection & preventionTypes of fire
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Fire & explosion hazards
Preventive measures• Prohibition of smoking in manufacturing areas.• Oxygen present in the inflammable atmosphere may
be ↓by dilution with gases such as nitrogen, co2,steam or combination of these.
• Hazardous operation should be isolated• Eliminating the ignition sources• Using fire resistant material in construction • Suitable emergency exits• Adequate venting
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Fire & explosion hazards
• Automatic sprinklers• Equipment should design to meet the specifications &
code of recognized authorities, such as ISA, API &ASME
• The design & construction of pressure vessels & storage tanks should follow API & ASME codes.
• Inspection
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Fire & explosion hazards
Chemical Hazards
Local
– Dermatitis
– Eczema
– Ulcers
– Cancer
Inhalation
– Gas Poisoning
Ingestion
Living tissue may be destroyed by chemical reactions such asDehydrationDigestion Oxidation
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Source, effect & precautions of chemical hazards
Type/ source of chemical contaminant
Effect/ organ affected
Precautions to be taken
Acridines, phenothiazines
Dermatitis Cleanliness, removal of people from the areas as soon as first sign of skin reaction is observed.
Solvents like chloroform, benzene
Handle with care
Vegetable drugs like capsicum & podophyllum
Dust evolves, affects eye
Goggles are to be worn
Long term use of filter without cleaning
Dust explosion Regular cleaning
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Source, effect & precautions of chemical hazards
Improper use of cleaning agents
contamination Follow established cleaning procedures
Working with radio pharmaceuticals
Hazards due to emitted radiation
Wearing lead coat, maintaining pressure of working area slightly less than atmospheric pressure
Underground tanks Difficulty in monitoring interior & exterior
Minimal use of underground tanks
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• Tolerance levels for toxic chemicals set by federal regulations have to be followed.
• Strict observation of operations of all safety regulations
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PREVENTIVE MEASURES
Biological hazards• Disease due to biological hazards Brucellosis (dairy industry) Byssinosis (textile industry) Bagassosis (sugar-cane) Loco motor disorder• Preventive measures
Periodic health check upPersonal protectionThe manufacturer should also provideFirst aid facilitiesInitial examinationFacility for vaccinationRoutine sanitation programme
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Mechanical hazards• Accidents usually take place by the combination of unsafe
condition & carelessness.• Most of industrial accidents are due to Faulty inspection Inability of employee Poor discipline Lack of concentration Unsafe practice Mental & physical unfitness for job Faulty equipment or improper working condition Improper training regarding the safety aspects
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•In order to prevent mechanical accidents factories act lay down certain requirements For cranesEnd buffersIndicating lampsSignalsProof loading upto20 tons 25% in excess 20 to 50 tons 5 tons in excess above 50 tons 10% in excess
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Mechanical hazards
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Mechanical hazards
Building planning• Floors must be of unskid/non-slippery type.
• Enough space for employees to work.
• Passages between working places.
• Proper arrangements of temperature control; like fans, A.C., heaters.
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Building planning
• Careless handling of heavy materials and components should be avoided.
• Full use of mechanical material handling equipment.
• All material handling equipments should be repaired and maintained properly.
• Containers employed to transport liquids should not be defective or leaking.
Safe material handling
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• Protection of head by using hard hats/helmets.
• Protection of ears by using earmufffs and plugs.
• Protection of face by using face marks, face shields.
Personal protective devices
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Electrical hazards• Shocks• Sparking• Fire• Wiring faults
Preventive measures Proper maintenance of wiring & equipment High voltage equipment should be properly enclosed Good house keeping Water should not be used for dousing electric fire Worker should avoid working in electric circuits or
equipment in wet clothing or shoes.
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Pollution hazards• Typesa. Air pollutionb. Water pollutionc. Thermal pollutiond. Sound pollution
Air pollution• Sources Automobiles Industries Domestic
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i. Those suitable for removing particulate matter a. Ventilation
Exhaust ventilation Plenum ventilation
b. Air purifying equipmentii. Those associated with removing gaseous pollutants Water pollution1. Types of water pollutants Physical Chemical Physiological Biological24 August 2012 32KLE College of Pharmacy, Nipani
Preventive measures
2. Problems of water pollution3. Preventive measure a. Control of water pollutioni. Physical treatment Storage Filtrationii. Chemical treatmentiii. Biological treatment b. Treatment of industrial waste
Primary treatmentSecondary treatmentTertiary treatment
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Preventive measures
c. Thermal pollution• Effects Damage to aquatic environment Reduction in assimilative capacity of organic waste
• Various off stream cooling systemsi. Wet cooling towersii. Dry cooling towersiii. Cooling pondsiv. Spray ponds24 August 2012 34KLE College of Pharmacy, Nipani
Preventive measures
Recommendations & suggestions
Proper treatment & disposal methods for effluents should be adopted
An awareness program
Measures for increase efficiency of the water use
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Classification of signs according to use – (1) Danger signs.
The DANGER header is used when there is a hazardous situation which has a high probability of death or severe injury. It should not be considered for property damage unless personal injury risk is present.
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2) Caution signs. (i)
The CAUTION header is used to indicate a hazardous situation which may result in minor or moderate injury. However, Caution should not be used when there is a possibility of death or serious injury.
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(3) Safety instruction signs
General Safety Signs (SAFETY FIRST, BE CAREFUL, THINK) should indicate general instructions relative to safe work practices, reminders of proper safety procedures, and the location of safety equipment.
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(4) Biological hazard signs.
The biological hazard warning shall be used to signify the actual or potential presence of a biohazard and to identify equipment, containers, rooms, materials, experimental animals, or combinations thereof, which contain, or are contaminated with, viable hazardous agents.
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Pictograph
Pictograph means a pictorial representation used to identify a hazardous condition or to convey a safety instruction
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Signal Word
Signal word means that portion of a tag's inscription that contains the word or words that are intended to capture the employee's immediate attention.
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Tag
Tag means a device usually made of card, paper, pasteboard, plastic or other material used to identify a hazardous condition.
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Danger Tags
Danger tags shall be used in major hazard situations where an immediate hazard presents a threat of death or serious injury to employees. Danger tags shall be used only in these situations.
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Caution TagsCaution tags shall be used in minor hazard situations where a non-immediate or potential hazard or unsafe practice presents a lesser threat of employee injury. Caution tags shall be used only in these situations.
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Warning TagsWarning tags may be used to represent a hazard level between "Caution" and "Danger," instead of the required "Caution" tag, provided that they have a signal word of "Warning," an appropriate major message
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Biological Hazard TagsThe symbol design for biological hazard tags shall conform to the design shown below:
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Color Coding-Danger Tag
"DANGER" -- Red, or predominantly red, with lettering or symbols in a contrasting color.
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Color Coding-Caution Tag
"CAUTION" -- Yellow, or predominantly yellow, with lettering or symbols in a contrasting color.
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Color Coding-Warning Tag
"WARNING" -- Orange, or predominantly orange, with lettering or symbols in a contrasting color.
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Biological Hazard TagBIOLOGICAL HAZARD -- Fluorescent orange or orange-red, or predominantly so, with lettering or symbols in a contrasting color.
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Industrial effluent testing and treatment• Effluent is an outflowing of water from a natural body
of water, or from a man-made structure.• Water pollution or waste water discharge from the
industrial facilities.REASON OF TESTING
• To find out-Pollution load -Presence of toxic ingredients -Color, turbidity, odour and quality of water -pH and acidity / alkalinity -Suspended solids and dissolved solids -Phenolic compounds and oily materials
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GUIDELINES FOR TESTING EFFLUENTS
• Samples may be collected at specific intervals and finally can be mixed before analysis.
• Containers made up of glass, polythene or any suitable plastic material may be used.
• Samples may also be refrigerated to avoid loss of volatile matter
• Samples could be preserved after adjusting the pH • O2, CO2, CO may be estimated
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• Effluents may be expressed as mg/ltr, ppm, %/ltr, and mcg/ltr
• Acidity / Alkalinity / Oil / Grease / CN / Phenol / Dyes content should be reported
TESTING OF WASTE WATER (EFFLUENT) TEST TREATMENT METHODpH
Acidic
Basic
Lime or NAOH
H2SO4
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THE RESULTS OF TESTING ARE REPORTED AS FOLLOWS:
Suspended Solids Sedimentation
Oil and grease -grease taps-skimming
CyanideChlorinated & complex with pyridine pyroxolene-Colourimetrically
-alkaline chlorination-oxidation with ozone-oxidation with H2O2
Phosphates-Convert to ammonium molybdatephosphates-extracted with benzene/ isobutyl alcohol mixture-organic phase treated with tin chloride (blue)Colourimetrically
-ppt with chalk or lime-coagulation with alum
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THE RESULTS OF TESTING ARE REPORTED AS FOLLOWS:
Mercury
-treated with nitric acid and potassium dichromate soln- treared with tin chloride
Vapour determined by spectrophotometry
-Coagulation
-chelation with trimercaptotriazine
Phenolic compounds
Steam distillation-acidify (pH<4)- add CuSO4
soln-
Add aminoantipyrine soln- extracted with chloroform
calorimetrically
Removal by polymeric adsorbents
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THE RESULTS OF TESTING ARE REPORTED AS FOLLOWS:
BIOLOGICAL OXYGEN DEMAND
• It is the amounts of oxygen required by micro organisms to bio chemically oxidize carbonaceous organic matter at 20 0C in 5 days.
• 10 mg/litre or less • Excess makes water toxic
MEASUREMENT
• Special designed bottle with flared cap• Incubated at 20 0C for 5 day measuring DO• Microorganism added if required
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Dissol oxy in ppm (mg/ltr) = N(V) (8) (1000) V1
V = Volume of sodium thio sulphate required.N = NormalityV 1= Volume of sample taken.
CHEMICAL OXYGEN DEMAND• Oxygen equivalent of organic matter present in waste water
that is susceptible to oxidation• Waste water sample is refluxed with a known excess of pot.
dichromate in a 50% sulphuric acid solution in presence of silver sulphate and mercuric sulphate
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• The organic matter of the sample is oxidised to water, carbon dioxide and ammonia
• The excess of dichromate remaining untreated in the solution is titrated against standard ferrous ammonium sulphate
• COD(mg/l) = (V1-V2) x N x 8 x100
XWhere,V1 = Volume of ferrous ammonium sulphate solution consumed in blank
V2 = Volume of ferrous ammonium sulphate solution consumed for test solution
X= Volume of sample takenN= Normality of ferrous ammonium sulphate solution24 August 2012 58KLE College of Pharmacy, Nipani
CHEMICAL OXYGEN DEMAND
Limit for Discharge into Systems
Sr. No. Parameters Tolerance limits1 pH 5.5 – 9.02 Oil and grease 103 Total suspended solid, mg/l 1004 BOD, mg/l 305 COD, mg/l 506 Mercury 0.017 Arsenic, mg/l 0.208 Cyanide, mg/l 0.109 Sulphides, mg/l 2.0010 Phosphates, mg/l 5.0024 August 2012 59KLE College of Pharmacy, Nipani
Waste Water Treatment Waste Water Pretreatment• Attempted to render the effluent suitable for further
treatment• Equalization Concentrated waste is diluted if necessary
-by mechanical mixing -by aeration mixing
• Neutralization • Removal of Grease and Oils
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Primary Treatment of Waste Water • Removal of large floating or suspended particle by
physical and chemical treatment Screening• Large particles are removed • Coarse screen of metal bars or heavy wires spaced 25-50
mm apart• Finer materials are separated by screening through 0.8-6
mm meshes Grit Chambers • Removal of particles by centrifugal action and friction
against tank walls• Diffused air used for mixing pattern24 August 2012 61KLE College of Pharmacy, Nipani
• It is used To prevent any damage to equipment To avoid settling in pipe bends
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Primary Treatment of Waste Water
Chemical Reaction• Involves agglomeration of tiny particles into large
particles Flocculation
-by mechanical stirring and by chemical flocculants Precipitation
-Large amount of suspended solid formed Coagulation
-Formation of large and quick settling flocs by a) Reduction of charges and repulsive forceb) Adsorption on long chain molecular structure
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Primary Treatment of Waste Water
Secondary Treatment of Waste Water• It is a biological process • C, H, and O sources are available • Nitrogen should be 5% of the BOD• Phosphorus should be 20% of mass of nitrogen• Environmental conditions are providedAdvantages• Continuous waste treatment is favored• Low cost systemDisadvantages• Prior prediction of biological degradability is not possible• Solubility limits biodegradability
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Activated Sludge Process• Microbial Floc is suspended in tank• Air is continuously supplied • Biological degradation of waste into CO2 and H2O • Bacterial flora grows and remains suspended in the form
of floc called as “activated sludge”• 20% of sludge is recycled • 6 to 24 hours aeration is required
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Secondary Treatment of Waste Water
• Advantages-Removal of soluble organic substance, colloidal matter, particulate matter, inorganic substance -Produce high quality effluent
• Disadvantage-Maintenance cost is high-Growth of anaerobic bacteria fungi etc
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Secondary Treatment of Waste Water
Activated Sludge Process
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• Microorganisms are attached to fixed bed• It acts as a filter• Bed is maintained at height of 2.5 meter• Gelatinous film is formed• Effluent is sprayed over the surface • Slots at the bottom for air inlet• Aerobic metabolism occur on the surface • Anaerobic metabolism occur at the bottom
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Trickling filtration process
Trickling Filtration Process
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Advantages• Produce effluent of consistent quality• Aerobic and anaerobic digestion are achieved• More economical• Sludge can be removed quickly
Disadvantage• Cost for ventilation duct for air supply is high• Efficiency decreases in the winter
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Trickling Filtration Process
Oxidation Ponds • Depth should be 1 to 2 meters.• Bottom and sides are lined with polyethylene, cement.• Oxygen released by algae, carbon dioxide generate from
biodegradative• Aerobic oxidation producing carbon dioxide and water. Advantage:• Operation is simple and economical.Disadvantages:• Required disinfections • Use for wastes having low BOD.
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Secondary Treatment of Waste Water
Tertiary Treatment Of Waste Water • Meant for polishing the effluents.• Bacteria are removed by keeping in maturation
ponds.• Chlorinated, if still contain bacteria.• Methods are more expensive than biological
treatment. Coagulation :• Reaction take place upon addition of the
coagulants.-Metal salts-Organic Polymers
• In water, form insoluble product with impurities.24 August 2012 72KLE College of Pharmacy, Nipani
Coprecipitation :• Ions in solution phase precipitate with the carrier
molecule by-Adsorption Process-Inclusion Process
Filtration • Most common type in addition to disinfection.• Practiced prior to the chlorination.• Should be done after coagulation.• May be made up of sand, activated charcoal.
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Tertiary Treatment Of Waste Water
Adsorption • Involves treatment with activated carbon.• Useful for removal of pesticides
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Tertiary Treatment Of Waste Water
REFRENCES• Pharmaceutical Production and Management By C. V. S. Subrahmanyam
• www.geocities.com
• www.britannica.com
• http://nptel:iipm.ac.in
• www.waste_management_world.com
• Sewage and Industrial Effluent Treatment, 2 nd edition By John Arundel
• The Theory & Practical of Industrial Pharmacy By Leon Lachman, Herbert A. Lieberman, Joseph Kiang, 3RD Edition Varghese Publishing House.
• www.osha.gov24 August 2012 75KLE College of Pharmacy, Nipani
THANK YOU
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Cell No: 00919742431000E-mail : [email protected]